Download AFD User`s Manual

SFS81 Series
Servo Finishing
Stand
P USH C ORP, I NC.
Dallas, Texas
May, 2012
NEVER OPERATE THE
SFS81 MANUALLY
NEVER OPERATE THE SFS81 WITH
PERSONEL IN THE WORKCELL
DO NOT USE LUBRICATED AIR.
This device requires a dry, non-lubricated
100 psi (6.9 bar) maximum air supply
filtered to 5 µm and a 0.3 micron oil mist
separator.
Non-compliance with these requirements
will void the manufacturer’s warranty.
(See Section 3.4)
All fasteners, mounting holes and pipe
threads on this tool are METRIC.
P USH C ORP, I NC. SFS81 Series Manual
1
Table of Contents
1.0 LIMITED WARRANTY.............................................................................................2
2.0 GENERAL OVERVIEW............................................................................................4
3.0 INSTALLATION........................................................................................................5
3.1 Mounting the SFS81......................................................................................................................... 5
3.2 Electrical Connections....................................................................................................................... 6
3.3 Electrical Control Box........................................................................................................................ 8
3.4 Pneumatic Connections.................................................................................................................... 8
4.0 OPERATION.............................................................................................................10
4.1 Media Mounting................................................................................................................................. 10
4.2 Achieving Desired Force................................................................................................................... 11
4.3 Achieving Desired Media Speed....................................................................................................... 11
4.4 Drive Belt Replacement.................................................................................................................... 11
4.5 Media Position Feedback.................................................................................................................. 11
5.0 TECHNICAL SPECIFICATIONS..............................................................................13
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
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1.0 Limited Warranty
Duration:
One year from date of delivery to the original purchaser.
Who gives this warranty (warrantor):
PushCorp, Inc.
Telephone: (972) 840-0208
Corporate Address:
P. O. Box 181915
Dallas, Texas 75218
Shipping Address:
3001 W. Kingsley Rd.
Garland, Texas 75041
Who receives this warranty (purchaser):
The original purchaser (other than for purposes of resale) of the PushCorp, Inc.
product
What products are covered by this warranty:
Any PushCorp, Inc. Adjustable Force Device or Adjustable Force Device
accessory supplied or manufactured by the Warrantor.
What is covered under this warranty:
Defects in material and/or workmanship which occur within the duration of the
warranty period.
What is NOT covered in this warranty:
A. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANT-ABILITY
AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO ONE
YEAR FROM THE DATE OF ORIGINAL PURCHASE. Some states do not
allow limitations on how long an implied warranty lasts, so the above
limitations may not apply to you.
B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE or
EXPENSE THAT MAY RESULT FROM ANY DEFECT, FAILURE,
MALFUNCTION OF THE PUSHCORP, INC. PRODUCT. Some states do not
allow the exclusion or limitation of incidental or consequential damages so
the above limitation or exclusion may not apply to you.
C. Any failure that results from an accident, purchaser's abuse, neglect,
unauthorized repair or failure to operate the products in accordance with the
instructions provided in the owner's manual(s) supplied with the product.
Responsibilities of the Warrantor under this warranty:
Repair or replace, at Warrantor's option, products or components which have
failed within the duration of the warranty period.
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
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Responsibilities of the purchaser under this warranty:
A. Deliver or ship the PushCorp, Inc. product or component to PushCorp, Inc.
Service Center, Dallas, TX. Freight and insurance costs, if any, must be
borne by the purchaser.
B. Use reasonable care in the operation and maintenance of the product as
described in the owner's manual(s).
When warrantor will perform repair or replacement under this warranty:
Repair or replacement will be scheduled and serviced according to the normal
work flow at the service center, and depending on the availability of replacement
parts. Purchasers requiring quicker repair may receive such with payment of a
PushCorp, Inc. predetermined expediting fee.
This Limited Warranty gives you specific legal rights and you may also have other rights
which vary from state to state.
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
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2.0 General Overview
The PushCorp SFS81 Series Servo Finishing Stand combines passive compliant force
control and closed-loop servo motor speed control technology. The SFS81 has been
designed from the ground up as a Finishing Stand for robotic applications with many
new and unique features.
Accurate force and speed control allows you to achieve unprecedented levels of quality
and consistency. The SFS81 enables maximum flexibility for any part-in-hand grinding,
sanding, buffing or polishing application. Linear compliance with 1.6 inches (40 mm) of
travel and excellent access allow a robot to easily manipulate parts over the Media. An
important feature of the SFS81 Finishing Stand is the high torque servo motor and belt
drive. The belt drive system provides a 2:1 increase in torque at the Media for heavy
material removal.
The force control technology in the SFS81 is based on the PushCorp Passive AFD80
Series Force Devices. This technology has proven itself in thousands of hours of
production robotic applications. The standard regulator supplied with the SFS81 allows
the force to be varied from 2 to 100 lbs. (8 to 445 N). This regulator has a coarse
adjustment and must be manually set to the desired force output. If the force must vary
during the finishing process, then an electrically controlled proportional regulator is
required. Very accurate force output requires a precision regulator that operates in a
narrow pressure range.
The electrical control box is mounted remotely from the Finish Stand outside the robot
enclosure to protect it from dust and vibration. Electrical interface cables are ordered
separately and can be made to any length up to 30 meters as required by the
customer's installation.
In most any finishing process, consistency is of paramount importance. For this reason
the SFS81 is powered by a high torque servo motor with adjustable speed control that
can be varied at any time during the finishing process. The SFS81 has a 6 horsepower
(4.5 kW) motor that supplies 16 lb •ft (22 N•m) of continuous torque and a maximum
rotational speed of 2000 RPM at the media mounting shaft. With dual 30mm shafts the
user can mix & match their Media allowing multiple finishing operations at the same
piece of equipment. This flexibility allows the SFS81 to perform a wide variety of
finishing applications.
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
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3.0 Installation
3.1 Mounting the SFS81
The SFS81 Servo Finishing Stand is secured by four (4) fasteners passing through
mounting holes located in the Base Plate. The Base Plate mounting hole locations are
shown in Figure 1. The SFS81 must be securely mounted to keep the unit from moving
during operation, and must be mounted level to achieve the desired force output. A
spirit level can be place on the top of the Finishing Stand and shims can be inserted
under the Base Plate as required.
WARNING: Do NOT operate the unit without first mounting it securely.
Figure 1. SFS81 Base Plate mounting holes
The SFS81 attaches with four (4) fasteners, 1/2 inch (12 mm) in diameter. These
fasteners are to be provided by the installer.
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
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3.2 Electrical Connections
The SFS81 requires 208 - 480 VAC, 3-Phase, 50-60 Hz. power to operate. This should
be supplied via conduit connection to the Control Box. The electrical connections are
made to the User Interface Blocks as shown in Figure 2.
Figure 2. User Interface terminal blocks
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
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Figure 3. SFS81 Typical User Interface Schematic
The circuit diagram in Figure 3 shows the SFS81 wired for stand-alone panel operation.
All digital I/O on the SFS81 is designed for 24 VDC control voltages.
The Mounting Shaft rotational speed is controlled via a 0 - 10VDC analog signal applied
to terminals 9 and 10. The analog input is a true floating differential signal connected
directly to the servo amplifier. The circuit shown in Figure 2 is an example of how the
shaft speed may be controlled with a simple panel mount linear potentiometer. If remote
robot teach pendent adjustment is desired, the potentiometer would be replaced with an
analog signal from a robot analog output card connected directly to Pins 9 and 10.
WARNING: The differential voltage applied to terminals 9 and 10 should not
exceed 10 VDC or damage will occur to the servo amplifier.
Terminal 7, shown in Figure 2 provides the servo amplifier enable signal. Connecting
Terminal 7 to +24VDC enables the servo amplifier and applies voltage to the servo
motor. Removing voltage from terminal 7 disables the amplifier.
The “DRIVE OK” output on Terminal 11 should be continuously monitored by the Enduser control system. This signal should be “ON” during normal operation. An “OFF”
condition indicates a drive fault. The cause of the fault will be indicated by a flashing
code on the servo drive amplifier.
OPERATION SHOULD CEASE UNTIL THE FAULT CONDITION IS CORRECTED.
The Electrical Control box includes a built-in E-Stop push button switch that, when
pressed, immediately removes all electrical power from the motor. If desired, the SBS81
can be connected to an external, dual-channel, E-Stop circuit by connecting to the
STO1 and STO2 signal on Terminals 3, 4, 5, and 6 as shown.
It is the responsibility of the System Integrator and/or End-user to follow all
applicable electrical codes and OSHA safety standards when wiring the SFS81.
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
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This includes the proper and judicious use of fuses, contactors, cut-off switches,
lock-out switches, and Emergency Stop circuits. PushCorp, Inc. assumes no
responsibility or liability for the electrical system design and implementation of
the SFS81 in the End-user application. Refer to OSHA rules and regulations, as
well as the CE Machinery Regulations (IEC 204-1), when designing systems that
include motors and drives to ensure that the user is protected.
PushCorp will provide answers to any questions regarding the servo drive system and
will be responsible for any warranty issues.
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
9
3.3 Electrical Control Box
The SFS81 Electrical Control Box is designed to be wall mounted outside the robot work
area in a relatively clean environment. Figure 4 shows the mounting dimensions of the
electrical enclosure.
Figure 4. Electrical Control Box Mounting
It is the responsibility of the installer to punch holes in the enclosure for conduit and/or
cord grips as required for the electrical supply power wiring and low-voltage control
signals.
3.4 Pneumatic Connections
The SFS81 Finishing Stand requires a dry, non-lubricated, 5 micron filtered, 80 to 100
psi (5 - 7 Bar) air supply with a 0.3 micron oil mist separator. Failure to provide supply
air to these specifications can degrade performance and will void any warranty repairs
concerning pneumatic components. Additionally, a minimum 80 psi (5 Bar) air pressure
must be maintained for the device to operate within published specifications. Low air
pressure will cause inferior force control performance.
The pneumatic supply system should be configured as shown in Figure 5.
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
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Figure 5. Pneumatic Connections
WARNING: If water condensation is present in your air supply system, an air dryer
device is highly recommended. Moisture inside the device will cause premature
failure that will not be covered under warranty.
The SFS81 Finishing Stand AFD maintains a positive air pressure to impede the
infiltration of contaminate materials. The amount of air entering the AFD is set by
adjusting the Flow Control Needle Valve located on the rear of the unit. It is important to
provide a continuous compressed air supply to the device at all times if the work
environment contains airborne contaminates. If the environment is clean during nonoperational periods, the air supply to the device may be shut off.
The SFS81 has one pneumatic input, an R 1/4 (Metric) port located on the SFS81
Regulator (Figure 5). This port supplies all the air needed to operated the Finishing
Stand. Before connecting the supply to the air fitting, open the supply valve to blow out
any contaminates which may be in the line. Charge the supply line with compressed air
and verify that there are no air leaks and that there is a minimum of 80 psi (5 Bar). If a
minimum air pressure of 80 PSI cannot be achieved, then an auxiliary air compressor or
booster pump must be installed.
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
11
4.0 Operation
4.1 Media Mounting
The SFS81 has dual 30mm diameter Mounting Shafts that protrude 10.6 in. (271 mm).
The user is responsible for choosing the appropriate means to attach their Media to the
Mounting Shafts. One option PushCorp recommends is to use an SKF 30mm Shaft Hub
(SKF Part # SHT30, PushCorp P/N PAR02456). These may be purchased directly from
SKF or through PushCorp. The hubs securely lock the Media Adapter Arbor to the
Output Shaft in a way that keeps the Media concentric to the Mounting Shaft and
transmits the required torque. Media adapter assemblies are not supplied with the
SFS81.
Figure 6, below, illustrates one method of mounting utilizing the SKF Shaft Hubs.
Figure 6. Example of Media mounting
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
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4.2 Achieving Desired Force
The SFS81 uses a modified passive 80 Series AFD to supply a compliant force from 2 to
100 lbs. (8 to 445 N). The passive force device requires the user to provide regulated air
pressure to achieve a desired force output at the Media. Use the following equations to
determine the pressure required to achieve the desired output force:
F = (1.4×P s) Applied Force (lbs)
F = (89×P s) Applied Force (N)
Where:
P s = Regulator pressure (PSI or Bar)
PushCorp has included a manual regulator to allow for quick set-up. This manually
adjustable pressure regulator may be sufficient, but if remote operation of the force
output is needed, then an electrically controlled proportional air regulator will be
required. The accuracy of the force output is directly related to the precision and quality
of the pressure regulator. A regulator that operates over a limited range (i.e., 0-15 psi) is
required for the most precise low force output.
4.3 Achieving Desired Media Speed
The Output Shaft rotational speed is controlled via a 0 - 10VDC analog signal applied to
Pins 9 and 10 of the User Interface Connector. The user must scale the command
voltage to the servo motor amplifier from 0 to 10 Volts, which commands an Output Shaft
rotational speed of 0 to 2000 rpm. The user is responsible for determining the maximum
allowable speed for their Media. The SFS81 is factory limited to operate at a maximum
Mounting Shaft rotational speed of 2000 rpm. Figure 2 shows a simple circuit using a
linear potentiometer to control Media speed, however most installations will require a
remote voltage command from a robot or PLC analog output card to vary the rotational
speed of the Media.
4.4 Drive Belt Replacement
The SFS81 uses a 2:1 reduction timing belt drive to transfer power from the Servo Motor
to the Mounting Shaft. This drive incorporates a high-strength Gates Poly Chain GT2
belt, PushCorp Part No. PAR01889-1. Should this Drive Belt ever require replacement,
contact PushCorp for the proper procedure.
4.5 Media Position Feedback
The SFS81 comes equipped with an internal potentiometer that provides a voltage
signal based on the linear position of the Media. The voltage signal is at a minimum
value when the Media is pushed back against the rubber stops, and a maximum value
when the Media is forward against the rubber stops. The total linear compliant stroke is
1.6 in. (40 mm).
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
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The linear position signal must be calibrated for each installation. User calibration is
easily accomplished using the following steps.
1. Turn off the supply air to the SFS81
2. Push the Media to the rearward (negative) position.
3. Read the voltage signal on Pin 12 of the User Interface Connector. Record
this voltage for future reference. This will be referred to as V n .
4. Pull the Media to the forward (positive) position.
5. Read the voltage signal on Pin 12 of the User Interface Connector. Record
this voltage for future reference. This will be referred to as V p .
6. The position of the Media can now be determined by measuring the voltage,
V m on Pin 12 of the User Interface Connector, and inserting the value into the
following equation:
p = 1.6in × (
V m−V n
) English units
V p−V n
p = 40mm × (
V m −V n
) Metric units
V p−V n
Where,
p = Media Wheel Position (in,mm)
V m = Voltage measured on Pin 12 (V)
V n = Calibrated voltage at rearward position (V)
V p = Calibrated voltage at forward position (V)
Copyright  PushCorp, Inc. 2012. All rights reserved
P USH C ORP, I NC. SFS81 Series Manual
14
5.0 Technical Specifications
Maximum Applied Force: 100 lbs. (445 N)
Weight:
370 lbs. (168 kg)
Force Scale Factor:
1.4 lbs/psi (890 N/MPa)
Compliant Stroke:
1.6 in. (40 mm)
Supply air:
Non-lubricated, Dry, 5µm Filtered, 100 psi (0.7 MPa) Max.
Supply Voltage:
208 - 480 VAC, 3-Phase
Max. Cont. Current:
30 Amps
Max. Peak Current:
60 Amps (2 Seconds)
Specifications subject to change without notice.
Fastener Tightening Torque Specs
Torque
Fastener Size
Minimum Depth
in.-lbs.
ft.-lbs.
N·m
in.
mm
M4 x .7
50
4.2
5.6
0.17
4.3
M5 x .8
85
7.1
9.6
0.21
5.3
M6 x 1
140
11.7
15.8
0.25
6.3
M8 x 1.25
348
29.0
39.3
0.33
8.4
M10 x 1.5
600
50.0
67.8
0.41
10.5
Copyright  PushCorp, Inc. 2012. All rights reserved